Active grille multi part modular frame

ABSTRACT

An active grille shutter arrangement having a modular frame. The active grille shutter arrangement includes a primary frame piece defining a width and height of an aperture of the modular frame, wherein in the primary frame piece has a motor housing, and upper frame portion having a first end and a second end, a lower frame portion having a first end and a second end and the motor housing extends between the upper frame portion and the lower frame portion. There is a plurality of secondary frame pieces that are adjustably connected to the primary frame pieces, thereby allowing the width of the modular frame to be adjusted.

FIELD OF THE INVENTION

The present invention relates to a multi piece modular frame for use inan active grille shutter system for a vehicle.

BACKGROUND OF THE INVENTION

Various attempts have been made to optimize the cooling of variousautomobile parts. Some of the various devices developed have beendesigned to control the air flow throughout the engine compartment ofthe automobile such that the desired amount of heat is transferred awayfrom the engine, transmission, and other components which generate heat,in order to maintain an optimal operating temperature.

However, it is also desirable to bring the engine up to the normaloperating temperature as soon as possible after engine start-up. Whenthe engine is substantially the same temperature as the surroundingenvironment and is turned on, the engine is the least fuel efficient(especially during start-up and the temperature of the surroundingenvironment is cold). The reduced fuel efficiency is why it isconsidered desirable to bring the engine up to the optimal operatingtemperature very quickly. Under these conditions, it is not desirable toremove heat away from the engine and the various components surroundingthe engine, and therefore devices designed to control air flow aroundthe engine are more beneficially used if they do not remove heat awayfrom the engine at start-up.

Active grille systems that have been developed implement a frame istypically molded as a complete part. During assembly, the frame and/orthe vanes have to be distorted in order to assemble the complete systemonto the one piece frame. Additionally, the one piece frame has a lowshipping density as it is mostly empty space. Furthermore, if an activegrille system has two variants with either additional vanes or a baseair flow, a complete new frame must be molded and shipped. It istherefore desirable to provide a frame that is multiple separate moldedparts instead of one complete molding. This will aid in the assembly ofthe active grille shutter system without having to distort the frames orthe vanes. Additionally, having multiple components accommodates thevarious variants that can be needed depending on the particularapplication. Lastly, having a multi-piece frame increases the shippingdensity since the various components can be stacked more closelytogether.

SUMMARY OF THE INVENTION

The present invention is directed to an active grille shutterarrangement having a modular frame. The active grille shutterarrangement includes a primary frame piece defining a width and heightof an aperture of the modular frame. There is further provided at leastone adjustable end cap connectable to the primary frame piece, whereinthe primary frame piece and the at least one adjustable end cap form themodular frame having at least one aperture capable of allowing air topass through the modular frame. Between the at least one adjustable endcap and the primary frame is a sliding joint that allows a portion ofthe at least one adjustable end cap or a portion of the primary frame toslide into the at least one adjustable end cap. The sliding jointprovides a plurality of lock positions for providing a plurality ofwidths of the active grille shutter arrangement. There is a plurality ofvanes rotatably positioned between the at least one primary frame pieceand the at least at least one adjustable end cap in order to open andclose the aperture of the modular frame, thereby controlling airflowthrough the active grille shutter arrangement. A motor housing of theframe piece is connected to and controls the rotation of the pluralityof rotatable vanes.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is an exploded angled perspective view of an active grilleshutter arrangement in accordance with the present invention;

FIG. 2A is an angled perspective view of the active grille arrangementin accordance with the present invention;

FIG. 2B is an angled perspective view of the active grille arrangementin accordance with another aspect of the present invention;

FIG. 2C is an angled perspective view of the active grille arrangementin accordance with another aspect of the present invention;

FIG. 3A is a front angled perspective view of the active grillearrangement in accordance with the present invention;

FIG. 3B is a rear angled perspective view of the active grillearrangement in accordance with the present invention;

FIG. 4 is an exploded rear perspective view of the modular frame inaccordance with an alternate embodiment of the present invention;

FIG. 5 is an enlarged perspective view of an end joint of the upperframe portion;

FIG. 6 is an enlarged perspective view of the assembled end joint andend cap joint in accordance with the present invention;

FIG. 7A is an exploded perspective angled view of an interlockingdovetail joint on the upper frame portion with the upper portion of themotor housing exploded from the interlocking dovetail joint;

FIG. 7B is an enlarged perspective view of the motor housing assembledto the interlocking dovetail joint of the upper frame portion;

FIG. 8A is a perspective view showing the assembly of the modular frame;

FIG. 8B is a perspective view showing the assembly of the modular frame;

FIG. 8C is a perspective view showing the assembly of the modular frame;

FIG. 8D is a perspective view showing the assembly of the modular frame;

FIG. 9 is an exploded perspective view of a third embodiment of theinvention;

FIG. 10 is an exploded perspective view of a fourth embodiment of theinvention;

FIG. 11 is an exploded perspective view of a fifth embodiment of theinvention;

FIG. 12 is an exploded perspective view of a sixth embodiment of theinvention;

FIG. 13 is an exploded perspective view of a seventh embodiment of theinvention including an alternate method of assembly; and

FIG. 14 is an exploded perspective view of an eighth embodiment of theinvention.

FIG. 15 is a rear perspective view of alternate embodiment of an activegrille shutter arrangement having two banks of vanes and adjustable endcaps with a slide joint.

FIG. 16 is an enlarged rear perspective view of the link and bridge usedto transfer rotational force between the two banks of vanes depicted inFIG. 15.

FIG. 17A is an enlarged exploded bottom perspective view of a slidingjoint used between an end cap and the primary frame shown in FIG. 15.

FIG. 17B is an enlarged exploded top perspective view of a secondsliding joint used between an end cap and the primary frame shown inFIG. 15.

FIG. 18 is an enlarged top perspective view of a sliding joint usedbetween the end cap and the primary frame shown in FIG. 15, shown in afirst position.

FIG. 19 is an enlarged top perspective view of a sliding joint usedbetween the end cap and the primary frame shown in FIG. 15, show in asecond position.

FIG. 20 is an enlarged bottom perspective view of a sliding joint usedbetween the end cap and the primary frame shown in FIG. 15, show in asecond position.

FIG. 21 is an enlarged bottom perspective view of a sliding joint usedbetween the end cap and the primary frame shown in FIG. 15, show in asecond position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring now to the figures generally and with reference to FIGS. 1-8D,an active grille shutter arrangement 10 having an modular frame 12, 112,212, 412, 512, 612 is depicted. The active grille shutter arrangement isdefined herein to be a modular frame 12, 112, 212, 412, 512, 612, inaccordance with one of the embodiments below, along with a motorassembly and vane as described below. Modular frame 12, 112, 212, 412,512, 612, which is shown in various views as being exploded,disassembled and assembled in other views. Referring to FIG. 4 anexploded view of the modular frame in accordance with one embodiment ofthe invention is shown. The modular frame includes an upper frameportion 14 having a first end 16 and second end 18, as well as a lowerframe portion 20 having a first end 22 and second end 24; a first endcap 26 and second end cap 28. The first end cap 26 and second end cap 28are connected to the upper frame portion 14 and lower frame portion 20to form the modular frame 12. As shown in the drawings, the shape of themodular frame 12 is generally rectangular; however, it is possible forthe structure to have different shapes depending upon the particularapplication. The upper frame portion 14, lower frame portion 20, firstend cap 26 and second end cap 28 are all formed of polymeric materialand in a preferred embodiment of the invention are created usinginjection molding. In order to strengthen these components, structuralribs 30 are present on the components in order to make them stronger andreduce the amount of polymeric material needed to create the specificcomponent.

When the upper frame portion 14, lower frame 20, first end cap 26 andsecond end cap 28 are assembled together to form the modular frame 12,one or more apertures, which in the present embodiment of the inventionis a first aperture 32 and second aperture 32′ created to allow air topass through the modular frame 12 when assembled to a vehicle. Theactive grille shutter arrangement 10 is created when the assemblemodular frame 12 has a plurality of vanes 34 connected between the firstend cap 26 and second end cap 28, which can be rotated in order tocontrol the amount of air flowing through the apertures 32. As shown inthe present invention, the vanes 34 are connected between a motorhousing or motor housing 36 extends between the upper frame portion 14and the lower frame portion 20. The vanes 34 are connected between themotor housing 36 and one of the first end caps 26 or second end cap 28and are configured to rotate about barrels 38 formed on each end of theplurality of vanes 34, such that the barrels 38 are rotatably disposedin holes 40 on the motor housing 36, first end cap 26 or second end cap28. Inside of the motor housing 36 is a motor or actuator 42 thatcontrols the rotatable position of the vanes 34 and thereby controls theamount of air flowing through the apertures 32.

The motor housing 36 is has an upper end 44 that connects to an upperframe center joint 46 of the upper frame portion 14. A lower end 48 ofthe motor housing 36 connects to a lower frame center joint 50 formed onthe lower frame portion 20. The connection between both the upper end44, upper frame center joint 46, lower end 48 and lower frames centerjoint 50 can be any type of suitable connection; however, the presentinvention provides an interlocking dovetail joint 52, which is bestshown in FIGS. 8a and 8n . Each interlocking dovetail joint 52 has aprotrusion 54 capable of sliding into a groove 56 for aligning andlocking the motor housing 36 to its respective upper frame portion 14 orlower frame portion 20. In order to lock the motor housing 36 togetherwith the upper frame portion 14 and lower frame portion 20. Eachinterlocking dovetail joint 52 also has a tab with a boss and fastenerarrangement 58 for locking the interlocking dovetail joint 52 in place.It is within the scope of this invention for some type of locking tab orother molded locking mechanism to be used instead of the tab, boss andfastener arrangement 58.

Referring to FIGS. 2A, 2B, 2C and 4, another aspect of the invention isshown that includes a modular frame kit 13 (shown in FIG. 4), includingparts of varying sizes used to create different modular frames. Themodular frame 12 is a first modular frame having a different height andwidth from a second modular frame 12′ or third modular frame 12″. Thefirst modular frame 12, second modular frame 12′ and third modular frame12″ are created by using the different alternate parts shown in FIGS.2A, 2B, 2C and 4, which include the upper frame portion 14, that is afirst upper frame portion, a second upper frame portion 14′, third upperframe portion 14″, the second lower frame portion 20 that is a firstlower frame portion, a second lower frame portion 20′, third lower frameportion 20″, vanes 34, that are a first vanes, second vanes 34′ andthird vanes 34″ (shown in FIGS. 2A, 2B and 2C) all of which havingdifferent widths. The modular frame kit 13 further includes end caps 26,28 that are a first set of end caps, a second set of end caps 26′, 28′and a third set of end caps 26″, 28″ each having different heights. Alsothe modular frame kit 13 includes the motor housing 36, which is a firstmotor housing, second motor housing 36′ and third motor housing 36″ eachhaving a different height and can be interchanged with the other partsof the modular frame kit to form the first modular frame 12, secondmodular frame 12′, third modular frame 12″ as shown in FIGS. 2A-2C.During assembly one upper frame portion, one lower frame portion, onemotor housing and one set of end caps is selected to create a desiredmodular frame construction. The selected one of the set of end caps isconnected to respective opposing ends of the one selected upper frameportion and one selected lower frame portion forming a generallyrectangular or square frame. The one selected motor housing is connectedbetween the one selected upper frame portion and the one selected lowerframe portion.

It is also within the scope of this invention for the parts of themodular frame kit 13 to be used in other combinations to create othermodular frame constructions having a height, width and shape that willvary depending on the different components used. It is further withinthe scope of this invention for the modular frame kit to have a greateror lesser number of alternate components having different dimensions andis not limited to just three alternative parts.

The modular frame kit 13 provides a great deal of versatility for thevarious components since the modular frames 12, 12′, 12″ can have adifferent size assembled from parts having different lengths. Thisallows the modular frame 12, 12′, 12″ to be used with various variantsencountered in and incorporating active grille shutter arrangements onvehicles. This also increases the shipping density of the components ofthe modular frame 12, 12′, 12″ by allowing similar parts to be packagedtogether more tightly than would be possible with a modular frame thatis one piece.

Referring now to FIGS. 5 and 6, the connection between the first andsecond ends 16, 18 of the upper frame portion and the first and secondends of the lower frame portion 22, 24 with each respective first endcap 26 and second end cap 28 are shown. The first end 16 of the upperframe portion 14 has an upper bar end joint 60 formed thereon which isconfigured to slide into an upper bar end cap joint 62 formed on thefirst end cap 26. The first end 22 of the lower frame portion 20 has alower bar end joint 64 formed thereon which slides into a lower bar endcap joint 66 of the first end cap 26. Similarly, the second end 18 ofthe upper frame portion 14 has an upper bar end joint 68 formed thereonand the second end 24 of the lower frame portion 20 has a lower bar endjoint 70 formed thereon. The upper bar end joint 68 of the second end 18of the upper frame portion 14 is configured to slide into an upper barend cap joint 72 of the second end cap 28. Also, the lower bar end joint70 on the second end 24 of the lower frame portion 20 slides into thelower bar end cap joint 74 of the second end cap 28. Once the upperframe portion 14 and lower frame portion 20 are connected to the firstend cap 26 and second end cap 28 as described above, the modular frame12 is complete.

Referring again to FIGS. 5 and 6, is an exploded exemplary view of theconnection between a respective one of the upper bar end joint 60, 68 orlower bar end joint 64, 70 with the respective upper bar end cap joints62, 72 or lower bar end cap joints 66, 74. The upper bar end joint 60,68 and lower bar end joint 64, 70 have show a protrusion that isconfigured to slide into a housing for receiving the protrusion as shownat the upper bar end cap joint 62, 72 and lower bar end cap joint 66,74. In order to lock all the pieces together, an end cap snap tab 76 isused to lockingly receive a frame bar snap post 78. While the drawingsof the present invention show the end cap snap tabs 76 as being formedon the lower bar end cap joint 66, 74 or upper bar end cap joint 62, 72and the frame bar snap post 78 being formed on the upper bar end joint60, 68 or lower bar end joint 64, 70, it is within the scope of theinvention for the end cap snap tab 76 and frame bar snap post 78 to bereversed and on opposing structures. Additionally, it is possible forother suitable injection molded locking mechanisms to be used includingtongue in groove type locks, as well as the use of adhesive ormechanical fasteners depending upon the needs of a particularapplication.

Referring now to FIGS. 1 and 3-8D, once the active grille shutterarrangement 10 has been fully assembled, the arrangement can beconnected to a vehicle using body mounts 80 which are holes used forconnecting the modular frame 12 using fasteners. However, it is possiblefor other types of connection mechanisms to be used such as adhesives,welding or other needs depending on a particular application. It is alsowithin the scope of this invention for the active grille shutterarrangement 10 to be connected to the vehicle chassis, front end moduleor the fascia of the vehicle.

Referring now to FIG. 2A, an assembled active grille shutter arrangement10 is shown having the having the specific valves 34 are shown. Theplurality of vanes 34 include a driving vane 84 connected to the motorand the other of the plurality of vanes are driven vanes 86 that aredriven by a link bar 88 connected to the driving vane 84. FIG. 2A showstwo driving vanes 84, located on opposite sides of the motor housing 36which allows for the two apertures of the modular frame to be opened andclosed independently of each other depending on the type of motor used.

Referring now to FIGS. 9-14 several alternate embodiments of the modularframe of the active grille shutter system 10 are shown and described. Ineach of these various embodiments the modular frame has a differentshape, and in other embodiments has differently shaped primary framepieces and secondary frame pieces, which are assembled together to formthe modular frame of the active grille shutter arrangement. Inparticular FIG. 9 shows an alternate embodiment of a modular frame 112having a primary frame piece 102 that is a one piece having the shape ofa capital letter “I” or capital letter “H”. The primary frame piece 102defines a width and height of an aperture 104 of the modular frame 112.The primary frame piece 102 in the present embodiment of the inventionis a single piece and further includes a motor housing 106, upper frameportion 108 and lower frame portion 110. The motor housing 106 extendsbetween the upper frame portion 108 and the lower frame portion 110 anddivides the aperture 104 in half. The modular frame 112 further includesa plurality of secondary frame pieces 127, 127 that include a first endcap 126 and second end cap 128. The first end cap 126 and second end cap128 are connectable to both the upper frame portion 108 and lower frameportion 110. The first end cap 126 connects to a first end 116 of theupper frame portion 108 and a first end 118 of the lower frame portion110. The second end cap 128 connects to a second end 120 of the upperframe portion 108 and a second end 122 of the lower frame portion 110.The manner in which the connection between the first end cap 112 andsecond end cap 114 with the primary frame piece is shown and describedabove with respect to FIGS. 5 and 6. The present embodiment of theinvention allows for the modular frame 112 to be formed from a fewernumber of pieces than the embodiments shown and described in FIG. 4.

Referring now to FIG. 11 an alternate embodiment of a modular frame 212is shown. The elements of a modular frame 112 are similar or identicalto those shown and described with respect to FIG. 9 above, thereforesimilar elements have been labeled using the same reference numerals. Inthe present embodiment of the invention a primary frame piece 202includes bridge elements 204, 206 that are formed as part of the primaryframe piece 202 or snapped onto the primary frame piece 202 in order tostabilize and prevent warping of the primary frame piece 202. Thestabilization and warping can occur during the formation of the primaryframe piece 202, which is typically formed from molten polymer, or thewarpage can result during transport, prior to assembly of the modularframe 200. The first end cap 112 and second end cap 114 are connected tothe primary frame piece 202 in the same manner as described above. Thebridge elements 204, 206 are formed onto the primary frame piece 202during molding or they may be connected to the primary frame piece 202after formation. The bridge elements can either stay in place uponconnection of the secondary frame pieces, such as the first end cap 126or second end cap 128 or they can be removed after connection of thefirst end cap 126 or second end cap 128.

Referring now to FIG. 10 another alternate embodiment of a modular frame312 is shown for an active grille shutter arrangement 300. In thisembodiment of the invention there is a primary frame piece 302 withthree sides including an upper frame portion 318, lower frame portion310 and a motor housing 306 that houses the motor for driving aplurality of vanes 326 in a manner similar to the embodiments describedabove. The motor housing 306 extends between the upper frame portion 318and the lower frame portion 310. The upper frame portion has an end 316and the lower frame portion has an end 320 that a secondary frame piece322, that is an end cap 324 similar to the first end cap and second endcap in the previous embodiments connects to form an aperture 304. Inthis embodiment of the invention the motor housing does not extendacross the aperture 304 of the modular frame 312. Vanes 326 extendacross the aperture 304 and rotatably connect to the motor housing 306and the secondary frame 322. The modular frame 312 in the presentembodiment of the invention is used in active grille shutterarrangements where it is desirable to not divide the aperture 304 inhalf using a motor housing. Also the vanes 326 are controlled by a motorand link bar which are shown and described in FIG. 2 above.

Referring now to FIG. 12 an alternate embodiment of a modular frame 512having a primary frame piece 502 that is one piece having the shape of acapital letter “T”. The primary frame piece 502 defines a width andheight of an aperture 504, 504′ of the modular frame 512. The primaryframe piece 502 in the present embodiment of the invention is a singlepiece and further includes a motor housing 506 and upper frame portion508. There is a secondary frame piece 509 having the shape of a capitalletter “U” and is a single piece having a lower frame portion 506 andupwardly extending first end portion 508 and second end portion 510. Thefirst end portion 508 and second end portion 510 each have a receivingend joint 513, 514 that face upward toward the primary frame piece 502.The upper frame portion 508 has downwardly facing post 516, 518 that arereceived by a respective receiving end joint 513, 514. The motor housing506 has a lower motor housing connection member 522 and connection point520 formed on the lower frame portion 506 that connects the motorhousing 506 to the secondary frame piece 509. The motor housing 506extends between the upper frame portion 508 and lower frame portion 506and defines the aperture 504,504′. The connection between eachdownwardly facing post 516, 518 and the receiving end joint 513, 514 andthe lower motor housing connection member 522 and connection point 520are not limited to any particular configuration but can be the types ofconnections shown and described in FIGS. 5, 6 and 7. The modular frame512 in the present invention can be assembled by vertically snapping theprimary frame piece 502 and the secondary frame piece 509 together.

FIG. 13 depicts an additional alternate embodiment of the modular frame512 shown in FIG. 12. In this embodiment a modular frame 612 a primaryframe piece 602 that is a one piece having the shape of a capital letter“T”. The primary frame piece 602 defines a width and height of anaperture 604 of the modular frame 612. The primary frame piece 602 inthe present embodiment of the invention is a single piece and furtherincludes a motor housing 606 and upper frame portion 608. There is asecondary frame piece 609 having the shape of a capital letter “U” andis a single piece having a lower frame portion 606 and upwardlyextending first end portion 608 and second end portion 610. The firstend portion 608 and second end portion 610 each have a receiving endjoint 613, 614 that face perpendicular to the plane of the aperture 604formed in the modular frame 612. The upper frame portion 608 has a post616, 618 that also face in a direction perpendicular to the aperture 604and are received by a respective receiving end joint 613, 614. The motorhousing 606 has a lower motor housing connection member 622 andconnection point 620 formed on the lower frame portion 606 that connectsthe motor housing 606 to the secondary frame piece 609. The motorhousing 606 extends between the upper frame portion 608 and lower frameportion 606 and divides the aperture 604 in half. The connection betweeneach post 616, 618 and the receiving end joint 513, 514 and the lowermotor housing connection member 622 and connection point 620 are notlimited to any particular configuration but can be the types ofconnections shown and described in FIGS. 5, 6 and 7. The modular frame612 in the present invention is assembled by horizontally snapping theprimary frame piece 602 and the secondary frame piece 609 together bymoving the piece perpendicular to the plane of the aperture 504 formedby the modular frame 512.

Referring to FIG. 14 an alternate embodiment of a modular frame 412 isshown. The modular frame 412 has a primary frame piece 403 that is asingle piece having a generally rectangular shape that defines anaperture 418,418′. While a rectangular shape is shown, it is within thescope of this invention for the modular frame 412 to have a differentshape, such as but not limited to a square, circle, trapezoid orvirtually any other type of shape. The primary frame piece 403 has anupper frame portion 402, lower frame portion 404. There is a first endportion 408 extending between the upper frame portion 402 and lowerframe portion 404 at one end and a second end portion 406 extendingbetween the upper frame portion 402 and lower frame portion 404 at asecond end. A secondary frame piece 409, which is a motor housing 410used to house an actuator for the active grille shutter system connectsto the upper frame portion 402 and at the lower frame portion 404. Themotor housing 410 has a lower motor housing connection member 416 thatconnects to a connection point 417 formed on the lower frame portion 404and an upper motor housing connection member 415 that connects to aconnection point 414 formed on the upper frame portion 402. Theconnections for the motor housing 410 can take any form but include allof the types of connections shown and described in FIG. 7.

FIG. 15 is a rear perspective view of alternate embodiment of an activegrille shutter arrangement 700 having two banks of vanes including anupper bank 701 and lower bank 703. The active grille shutter arrangement700 also includes adjustable end caps 716, 718, 720, 722 each having twosliding joints 724, 724′, 724″, 724′″, 726, 726′, 726″. 726′″. The topbank 706 and bottom bank 708 are arranged in parallel above and beloweach other and define apertures through the active grille shutterarrangement similar to previous embodiments. The width of the assembledactive grille shutter arrangement 700 is adjustable. Width is defined asleft to right as shown in FIG. 15, which can be adjusted using theadjustable end caps 716, 718, 720, 722.

Each of the adjustable end 716, 718, 720, 722 are U-shaped and connectto two locations on a primary frame 702. The end cap 716 connects to atop member 728 of the top bank 701 of the primary frame 702 at a firstsliding joint 724 and the end cap 716 connects to a bottom member 730 ofthe top bank 701 of the primary frame 702 at a second sliding joint 726.

The adjustable end cap 720 connects to the primary frame 702 at theopposite side of the end cap 716 in a similar manner using equivalentsliding joints 724′, 726′. The end cap 720 connects to the top member728 of the top bank 701 of the primary frame 702 at a third slidingjoint 724′ and the end cap 720 connects to the bottom member 730 of thetop bank 701 of the primary frame 702 at a fourth sliding joint 726′.

The bottom bank 703 of vanes has two adjustable end caps 718, 722 thatconnect in a manner similar to the adjustable end caps 716, 720 of thetop bank 701 of vanes. The adjustable end cap 718 connects to a topmember 728′ of the bottom bank 703 of the primary frame 702 at a fifthsliding joint 724″ and the end cap 718 connects to a bottom member 730′of the bottom bank 703 of the primary frame 702 at a sixth sliding joint726″. Adjustable end cap 722 connects to the top member 728′ of thebottom bank of vanes 703 of the primary frame at a seventh sliding joint724′″. The adjustable end cap 722 connects to the bottom member 730″ ofthe bottom bank of vanes 703 of the primary frame at an eighth slidingjoint 726′″. Each of the adjustable end caps 716, 718, 720, 722 areadjustable relative to the primary frame 702 in order to make theassembled active grille shutter arrangement 700 have an adjustable withthereby allowing different sized active grille shutter arrangements tobe made using the same components. It is also within the scope of thisinvention for the adjustable end caps 716, 718, 720, 722 have varyingsizes allowing for additional widths to be achieved. The actualadjustment of the adjustable end cap 716, 718, 720, 722 using thesliding joints 724, 724′, 724″, 724′″, 726, 726′, 726″, 726′″ which willbe discussed in greater detail below.

Referring now to FIG. 15 and FIG. 16, the operation of the vanes locatedin the top bank 701 and bottom bank 703 is accomplished using a singleactuator 709 located within the top bank of vanes 701. The singleactuator drives one of the vanes, which is referred to as a driven vane.The movement of the driven vein is transmitted to all of the other vanesin the top bank 701 through a link 710. The link 710 is configured tomove upward and downward as shown in FIGS. 15 and 16. The vanes locatedin the bottom bank of vanes 703 are also rotatably driven and connectedto a link 712 that is configured to move upward and downward in thedrawing shown in FIGS. 15 and 16. The link 712 is operably connected tothe actuator 709 through a bridge link 714 that connects between link710 and 712. The bridge link 714 spans across a mid-section 711 of theframe 702 that separates the top bank of vanes 701 from the bottom bankof vanes 703. The mid-section 711 also includes the top member of thebottom bank 728′ and the bottom member 730 of the top bank 701. Thus asingle actuator can be used to drive the vanes in both the top bank 701and bottom bank 703. It is within the scope of this invention foradditional actuators to be used in order to control the banks of vanesindependently.

Connected about the frame 702 are sealing panels 704, 704′ that are usedto provide a more airtight connection to the vehicle. The ceiling panels704, 704′ also assist in connecting the active grille shutterarrangement 700 to the vehicle by providing attachment points 707.

FIG. 17A is an enlarged exploded bottom perspective view of the slidingjoint 724, 724′, 724″, 724′″ between the end cap 716, 718, 720, 722 andthe top member 728, 728′ of the active grille shutter arrangement 700shown in FIG. 15. Each end cap 716, 718, 720, 722 has an arm 734 with aposition tabs 741, 742 on one side and a rib 736 on the side of the arm734 opposite the position tabs 741, 742. The arm 734 is sized to slideinto an aperture 738 defining an opening to a hollow 739 in the topmember 728, 728′. The aperture 738 and hollow 739 have a groove 740 thatis configured to receive the rib 736, which provide both alignmentduring assembly of the end cap 716, 718, 720, 722 to the top member 728,728′ as well as providing a sealing surface to which the rotating vanesof the active grille shutter arrangement 700 can rest against to createa tight seal between the vanes and the top member 728, 728′.

FIG. 17B is an enlarged exploded top perspective view of the slidingjoint 726, 726′, 726″, 726′″ between the end cap 716, 718, 720, 722 andthe bottom member 730, 730′ of the active grille shutter arrangement 700shown in FIG. 15. Each end cap 716, 718, 720, 722 has an arm 734′ with aposition tabs 741′, 742′ on one side and a rib 736′ on the side of thearm 734′ opposite the position tabs 741′, 742′. The arm 734′ is sized toslide into an aperture 738′ defining an opening to a hollow 739′ in thebottom member 730, 730′. The aperture 738′ and hollow 739′ have a groove740′ that is configured to receive the rib 736′, which provide bothalignment during assembly of the end cap 716, 718, 720, 722 to thebottom member 730, 730′ as well as providing a sealing surface to whichthe rotating vanes of the active grille shutter arrangement 700 can restagainst to create a tight seal between the vanes and the bottom member730, 730′.

Referring to FIGS. 15, 18 and 19 the details of the sliding joint 724,724′, 724″, 724′″ in a first position and second position are shown. Thefirst position and second position allow the width of the active grilleshutter arrangement 700 to be adjusted between preset locking positions,thereby changing the width of the active grille shutter arrangement 700without requiring different sized pieces. Once the arm 734 is insertedinto the aperture 738 and slides into the hollow the arm 734 can belocked into place using a resilient tab 744 located on the top member728, 728′, which engages either the position tab 741, 742 which preventsthe arm 734 from sliding out of the hollow 739. The arm 734 can then bemore permanently locked in place using adhesives or by placing afastener 749 into a hole 748. The position tabs 741 is located as adifferent position on the arm 734 than position tab 742, the purposebeing to allow the arm 734 to be placed at different locations in thehollow 739. The position tab 742 also has a corresponding fastener hole746 adjacent the position tab 742 that will be aligned with the hole 748when the resilient tab 744 engages the position tab 742. This allow thefastener 749 to be connected to the arum 734 using the fastener hole746. There is also a fastener hole (now shown) located in acorresponding location near position tab 741, which aligns with thefastener hole 748 when the resilient tab 744 is in contact with theposition tab 741.

While the present embodiments of the invention shows the position tabs741, 742, fastener hole 746 and rib 736 located on the arm 734 and theresilient tab 744, hollow 739 and groove 740 located on the top member728, 728′; it is within the scope of this invention for the componentsto be reversed between the arm 734 and the top member 728, 728′depending on the need of a particular application.

Referring to FIGS. 15, 20 and 21 the details of the sliding joint 726,726′, 726″, 726′″ in a first position and second position are shown.Once the arm 734′ is inserted into the aperture 738′ and slides into thehollow the arm 734′ can be locked into place using a resilient tab 744′located on the bottom member 730, 730′, which engages either theposition tab 741′, 742′ which prevents the arm 734′ from sliding out ofthe hollow 739′. The arm 734′ can then be more permanently locked inplace using adhesives or by placing a fastener 749′ into a hole 748′.The position tab 741 is located at a different position on the arm 734′than position tab 742′; the purpose being to allow the arm 734′ to beplaced at different locations in the hollow 739′. The position tab 742′also has a corresponding fastener hole 746′ adjacent the position tab742′ that will be aligned with the hole 748′ when the resilient tab 744′engages the position tab 742′. This allow the fastener 749′ to beconnected to the arm 734′ using the fastener hole 746′. There is also afastener hole (now shown) located in a corresponding location nearposition tab 741′, which aligns with the fastener hole 748′ when theresilient tab 744′ is in contact with the position tab 741′.

While the present embodiments of the invention shows the position tabs741′, 742′, fastener hole 746′ and rib 736′ located on the arm 734′ andthe resilient tab 744′, hollow 739′ and groove 740′ located on thebottom member 730, 730′; it is within the scope of this invention forthe components to be reversed between the arm 734′ and the bottom member730, 730′ depending on the need of a particular application.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. An active grille shutter arrangement having anmodular frame comprising: a primary frame having an upper bank having anaperture with a plurality of vanes extending across the aperture androtatably connected together by a first link and a lower bank having anaperture with a plurality of vanes extending across the aperture androtatably connected together by a second link, where the lower bank ispositioned below the upper bank; a top member of the primary frameforming a top side of the upper bank; a bottom member of the primaryframe forming a bottom side of the lower bank; a mid-section of theprimary frame forming a top side of the bottom side of the upper bankand a bottom side of the upper bank; a plurality of end caps eachconnected to two locations on the primary frame, wherein each side ofthe upper bank has one of the plurality of end caps connected to topmember and the mid-section to form a respective first side and secondside of the upper bank and each side of the bottom bank has one of theplurality of end caps connected to the mid-section member and the bottomside of the to form a respective first side and second side of the lowerbank; a motor connected to one of the vanes of the upper bank or lowerbank and causes the vanes of the upper bank or the lower bank to rotateby moving the first link of the second link; and a bridge link spanningacross the mid-section and connecting between the first link and thesecond link for transferring power from the motor.
 2. The active grilleshutter arrangement of claim 1 further comprising: a sliding jointbetween each plurality of end caps and the connection with the primaryframe that allows a portion of each plurality of end caps or a portionof the primary frame to slide into the plurality of end caps, whereinthe sliding joint provides a plurality of lock positions for providing aplurality of widths of the active grille shutter arrangement; and aresilient tab located on the primary frame piece at each sliding joint,where the resilient tab is configured to engage one of two or moreposition tabs formed on the plurality of end caps to prevent theplurality of end caps from sliding out of the hollow of the primaryframe piece.
 3. The active grille shutter arrangement of claim 2 whereineach sliding joint further comprises: at least one arm of the pluralityof end caps, the at least one arm has a rib; and an aperture in theprimary frame piece that defines an opening to a hollow primary framepiece, where the aperture and hollow frame piece have a groove that isconfigured to receive the rib of the at plurality of adjustable end capsto provide alignment during assembly of the plurality of adjustable endcaps to the primary frame piece.
 4. The active grille shutterarrangement of claim 3 further comprising: a hole adjacent each of thetwo or more position tabs for receiving a fastener to lock the pluralityof adjustable end caps and the primary frame piece together.
 5. Theactive grille shutter arrangement of claim 1, further comprising a motorhousing extending across the aperture of the upper bank or the lowerbank and dividing the aperture of the upper bank or the aperture of thelower bank into two sections, where each of the two sections has aplurality of vanes.
 6. The active grille shutter arrangement of claim 5,wherein the motor housing does not extend across the aperture of theupper bank or the aperture of the lower bank.
 7. The active grilleshutter arrangement of claim 1 further comprising: one or more bridgeson the primary frame piece for stabilizing the primary frame piece frameportion prior to connection of the plurality of end caps.
 8. The activegrille shutter arrangement of claim 1 further comprising: wherein eachone of the plurality of vanes has two ends with barrels formed on eachof the two and ends; and holes formed on the primary frame piece and oneof the plurality of end caps to rotatably receive one of said barrels ofone of said plurality of vanes.
 9. An active grille shutter arrangementhaving an modular frame comprising: a primary frame having an upper bankhaving an aperture with a plurality of vanes extending across theaperture and rotatably connected together by a first link and a lowerbank having an aperture with a plurality of vanes extending across theaperture and rotatably connected together by a second link, where thelower bank is positioned below the upper bank; a top member of theprimary frame forming a top side of the upper bank; a bottom member ofthe primary frame forming a bottom side of the lower bank; a mid-sectionof the primary frame forming a top side of the bottom side of the upperbank and a bottom side of the upper bank; a plurality of end caps eachconnected to two locations on the primary frame, wherein each side ofthe upper bank has one of the plurality of end caps connected to topmember and the mid-section to form a respective first side and secondside of the upper bank and each side of the bottom bank has one of theplurality of end caps connected to the mid-section member and the bottomside of the to form a respective first side and second side of the lowerbank; a motor housing having an upper end connected to an upper framecenter joint formed on the top member of the upper bank and a lower endof the motor housing connected to the mid-section of the primary frameforming the bottom side of the upper bank at a lower frame center,wherein the connection between the motor housing at the top member andthe mid-section are each an interlocking dovetail joint secured with atab and boss connected together with a fastener when the tab and bossare aligned; a motor positioned within the motor housing, the motor isconnected to one of the vanes of the upper bank and causes the vanes ofthe upper bank to rotate by moving the first link; and a bridge linkspanning across the mid-section and connecting between the first linkand the second link for transferring power from the motor.
 10. Theactive grille shutter arrangement of claim 9 further comprising: asliding joint between each plurality of end caps and the connection withthe primary frame that allows a portion of each plurality of end caps ora portion of the primary frame to slide into the plurality of end caps,wherein the sliding joint provides a plurality of lock positions forproviding a plurality of widths of the active grille shutterarrangement; and a resilient tab located on the primary frame piece ateach sliding joint, where the resilient tab is configured to engage oneof two or more position tabs formed on the plurality of end caps toprevent the plurality of end caps from sliding out of the hollow of theprimary frame piece.
 11. The active grille shutter arrangement of claim10 wherein each sliding joint further comprises: at least one arm of theplurality of end caps, the at least one arm has a rib; and an aperturein the primary frame piece that defines an opening to a hollow primaryframe piece, where the aperture and hollow frame piece have a groovethat is configured to receive the rib of the at plurality of adjustableend caps to provide alignment during assembly of the plurality ofadjustable end caps to the primary frame piece.
 12. The active grilleshutter arrangement of claim 11 further comprising: a hole adjacent eachof the two or more position tabs for receiving a fastener to lock theplurality of adjustable end caps and the primary frame piece together.13. The active grille shutter arrangement of claim 9, wherein the motorhousing extends across the aperture of the upper bank and divides theaperture of the upper bank into two sections, where each of the twosections has a plurality of vanes.
 14. The active grille shutterarrangement of claim 13, wherein the motor housing does not extendacross the aperture of the upper bank.
 15. The active grille shutterarrangement of claim 9 further comprising: one or more bridges on theprimary frame piece for stabilizing the primary frame piece frameportion prior to connection of the plurality of end caps.
 16. The activegrille shutter arrangement of claim 9 further comprising: wherein eachone of the plurality of vanes has two ends with barrels formed on eachof the two and ends; and holes formed on the primary frame piece and oneof the plurality of end caps to rotatably receive one of said barrels ofone of said plurality of vanes.